Process And System For Depositing Filling On A Biscuit

ABSTRACT

A method for the production of a food item having a filling includes conveying a food item to a first filling station. The filling station has a first rotating stencil with a first plurality of filling discharge ports. At least one first filling segment is formed by discharging filling, through the discharge ports, onto the food item. The food item is conveyed to a second filling station. The second filling station has a second rotating stencil with a second plurality of filling discharge ports. At least one additional filling segment is formed by discharging filling, through the second plurality discharge ports, onto the food item wherein the at least one additional filling segment is disposed on the food item adjacent to the at least one first filling segment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 61/776,345 filed Mar. 11, 2013 entitled “Process AndSystem For Depositing Filling On A Biscuit”, which is incorporated byreference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to the continuous production of a foodproduct that includes, for example, a sandwich having a plurality offilling segments disposed therein, the filling segments beingsubstantially uniform and having different organoleptic properties.

BACKGROUND OF THE INVENTION

Sandwich cookies and crackers can have a variety of shapes andconfigurations. Examples of such configurations include elongate orrectangular biscuits with filling disposed between the biscuits. It issometimes desirable to include multiple fillings in a biscuit sandwich.Depositing multiple fillings on a biscuit can be challenging, forexample, in a continuous high volume continuous production system wherethe biscuit is elongate and the fillings have different viscosities andlarge volumes of evenly distributed fillings are desired.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, there is a method for the production of a food itemhaving a filling. The method may further include conveying a food itemto a first filling station where the first filling station has a firstrotating stencil with a first plurality of filling discharge ports. Themethod may further include forming at least one first filling segment bydischarging filling, through the discharge ports, onto the food item. Afurther step may include conveying the food item to a second fillingstation where the second filling station has a second plurality offilling discharge ports. In one embodiment, the method may furtherinclude forming at least one additional filling segment by dischargingfilling, through the second plurality discharge ports, onto the fooditem wherein the at least one additional filling segment is disposed onthe food item adjacent to the at least one first filling segment.

In one aspect of the invention, the first plurality of filling dischargeports is arranged in an array. In one embodiment, the array is aconfigured in one of a row, a circle, an ellipse, a square, a rectangle,and an irregular pattern. In a further aspect of the invention, thesecond plurality of filling discharge ports may be arranged in a secondarray. In a still further aspect of the invention, the first array andthe second array are configured and dimensioned to deposit the at leastone first filling segment adjacent to the at least one additionalfilling segment. In yet another embodiment, the at least one firstfilling segment comprises two filling segments and the at least oneadditional filling segment is interposed between the two fillingsegments. In a further embodiment, the at least one first fillingsegment is deposited onto the food item in a first pattern and whereinthe at least one additional filling segment is deposited onto the fooditem in a second pattern that abuts but does not overlap the firstpattern. In one embodiment, the first pattern includes a first pluralityof substantially parallel rows and the second pattern comprises at leastone additional row that is substantially parallel to the first pluralityof rows. In another embodiment, the first pattern includes an openperimetrical shape and the second pattern is disposed within the openperimetrical shape. For example, in one embodiment, the openperimetrical shape is one of a square, a circle, an ellipse and an ovalhaving a continuous substantially uniformly deposited filling segmentsurrounding an open area on the food product that is substantially freeof filling. In one embodiment, the at least one first filling segmenthas a first organoleptic property and the at least one additionalfilling segment has a second organoleptic property.

One method of present invention includes conveying a food item to afirst filling station, the filling station having a first rotatingstencil with two spaced apart rows of filling discharge ports, each rowcomprising a plurality of filling discharge ports disposed on thecircumference of the first rotating stencil; forming two fillingsegments by discharging filling, through the two rows of fillingdischarge ports, onto the food item; conveying the food item to a secondfilling station, the second filling station having a second rotatingstencil with a third row of filling discharge ports, the third row offilling discharge ports comprising a plurality of discharge portsdisposed on the circumference of the second rotating stencil; andforming a third filling segment by discharging filling, through thethird row of filling discharge ports, onto the food item.

In one embodiment, the filling discharged through second filling stationis deposited between the two filling segments. In a further embodiment,the two filling segments are deposited onto the food item after thethird filling segment is deposited onto the food item. In oneembodiment, the food item is a baked good having a rectangularconfiguration and the step of forming two filling segments furtherincludes depositing filling longitudinally onto the baked good such thatthe two filling segments are substantially parallel. In anotherembodiment, each of the two spaced apart rows of the filling dischargeports comprise an array of substantially round discharge ports, eachsubstantially round discharge port being substantially evenly spacedapart in each row and wherein each array is disposed on only onehemisphere of the first rotating stencil. In another embodiment, thethird row of filling discharge ports include an array of substantiallyoval-shaped discharge ports, each substantially oval-shaped dischargeport having a major axis that is oriented transverse to thecircumference of the second rotating stencil, the oval-shaped dischargeports being evenly spaced apart in the third row and the array ofsubstantially oval-shaped discharge ports is disposed on only onehemisphere of the second rotating stencil.

In a further embodiment, the second rotating stencil further includestwo channels circumferentially disposed on an outer surface of thesecond rotating stencil, the third row of filling discharge ports beingdisposed between the two channels, the two channels being aligned withthe two spaced apart rows of the first rotating stencil such that inoperation the two filling segments discharged through the two rows offilling discharge ports of the first rotating stencil align with the twochannels as the food item passes the second filling station. In afurther embodiment, for example, the second rotating stencil includes arib disposed between the two channels, the third row of fillingdischarge ports being disposed on the rib. In yet another embodiment,the first rotating stencil operates in coordination with the secondrotating stencil such that the two filling segments and the thirdfilling segment are deposited onto the food item in a substantiallyuniform volume and in a substantially parallel configuration.

In one embodiment of the present invention, there is a system for theproduction of a food item having a filling thereon. One embodiment ofthe system includes a first filling station having a first rotatingstencil with two spaced apart rows of filling discharge ports, each rowcomprising a plurality of discharge ports disposed on the circumferenceof the first rotating stencil; a second filling station having a secondrotating stencil with a third row of filling discharge ports, the thirdrow comprising a plurality of discharge ports disposed on thecircumference of the second rotating stencil; and a conveyor configuredto pass a food item in alignment with the first filling station and thesecond filling station.

In one embodiment of the system, the first rotating stencil isconfigured and dimensioned to evenly deposit two substantially parallelrows of filling on the food item. In another embodiment, each of the twospaced apart rows of the filling discharge ports comprise an array ofsubstantially round discharge ports, each substantially round dischargeport being substantially evenly spaced apart in each row and whereineach array is disposed on only one hemisphere of the first rotatingstencil. In yet another embodiment, the third row of filling dischargeports include an array of substantially oval-shaped discharge ports,each substantially oval-shaped discharge port having a major axis thatis oriented transverse to the circumference of the second rotatingstencil, the oval-shaped discharge ports being evenly spaced apart inthe third row and wherein the array of substantially oval-shapeddischarge ports is disposed on only one hemisphere of the secondrotating stencil. In a still another embodiment, the second rotatingstencil further includes two channels circumferentially disposed on anouter surface of the second rotating stencil, the third row of fillingdischarge ports being disposed between the two channels, the twochannels being aligned with the two spaced apart rows of the firstrotating stencil such that in operation the two filling segmentsdischarged through the two rows of filling discharge ports of the firstrotating stencil align with the two channels as the food item passes thesecond filling station. In yet another embodiment, the second rotatingstencil further includes a rib disposed between the two channels, thethird row of filling discharge ports being disposed on the rib. Thesystem of the present invention may further include a controllerconfigured to rotate the first rotating stencil and the second rotatingstencil in coordination such that three rows of three filling segmentsare longitudinally deposited onto the food item at a substantiallyuniform volume and in a substantially parallel configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a food product of one embodiment of thepresent invention.

FIG. 2 is a perspective view of the food product shown in FIG. 1 with atop biscuit removed.

FIG. 3 is a front elevational view of a stencil of one embodiment of thepresent invention.

FIG. 4 is a side cross sectional view of the stencil of FIG. 3 takenalong line 4-4.

FIG. 5 is perspective view of a stencil of one embodiment of the presentinvention.

FIG. 6 is perspective view of the stencil of FIG. 5 shown during use.

FIG. 7 is front elevational view of a stencil of one embodiment of thepresent invention.

FIG. 7A is side cross sectional view of the stencil of FIG. 7 takenalong line 6-6.

FIG. 8A is perspective view of a stencil of one embodiment of thepresent invention.

FIG. 9 illustrates a perspective view of a system of one embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

Food products such as sandwich cookies and crackers may be continuouslyproduced in a high speed production system. Among the products that canbe produced from the systems and methods disclosed herein are elongatebiscuit sandwiches having two or more different fillings. The biscuitsare not limited to rectangular shapes, however, and may have otherelongate shapes including oval or racetrack shaped biscuits. In one suchhigh speed production system, a first biscuit portion (e.g., crackersand cookies) or base cake of the food product is transmitted by conveyorto a plurality of filling stations (e.g., in-line filling stations)where a plurality of prepared fillings are applied to one side of thebiscuit to form a topped base cake. The topped base cake may then travelto another station where a second biscuit caps the topped first biscuitto complete the sandwich. Fillings may be applied to a base cake using arotating stencil system. Large volumes of filler or crème can be appliedto a bottom base cake (e.g., a biscuit). The volume of filler depositedon each bottom base cake may be at least about 1.5 cubic inches, forexample at least 1.75 cubic inches and the deposited filler may have alength to width ratio of at least about 2:1, preferably at least about2.5:1. The base cakes and ribbon filler may be elongated in thedirection of product travel during deposition of the ribbon filler.

In one embodiment, filling stencils are retrofit to operate on astandard sandwiching machine such as those supplied by APV,Baker-Perkins or Peters/Peerless.

Exemplary systems for conveying prepared fillings to a filling stencilare disclosed in U.S. Pat. No. 4,469,021 granted Sep. 4, 1984 to Rose etal., U.S. Pat. No. 5,974,958 granted Nov. 2, 1999 to Lilley et al.; U.S.Pat. No. 4, 162, 882 granted on Jul. 31, 1979 to Rose, and U.S. Pat. No.4,708,054 granted on Nov. 24, 1987 to Newbery et al. each such documenthereby being incorporated by reference in its entirety herein.

Among the products that can be produced from the systems and methodsdisclosed herein are elongate biscuit sandwiches having two or moredifferent fillings. The biscuits are not limited to rectangular shapes,however, and may have other elongate shapes including oval or racetrackshaped biscuits.

The continuous systems and method disclosed herein may produce biscuitsandwiches having filling deposited therein. In one embodiment, thefilling is deposited as segments on the base cake. The filling segmentsmay, for example, be deposited in longitudinal strips. The longitudinalstrips may include parallel strips. The longitudinal strips may furtherbe substantially uniform in volume, area and/or cross section along thelength of the strip. Two or more of the strips may be applied to abiscuit and those two or more strips may each have a different flavor.

FIGS. 1 and 2 illustrate one embodiment of a food product 100. Foodproduct 100 includes two biscuits 102 and three filling strips 104 a,104 b, and 104 c. The food products 100 of the present invention mayinclude more or fewer filling strips. For example, in an embodimentillustrated in FIG. 2, there is a portion of a food product 100 thatincludes a biscuit 102 and three filling segments 104 a, 104 b, and 104c deposited thereon. In a preferred embodiment, each of the fillingsegments 104 a, 104 b, and 104 c is deposited onto a biscuit 102 suchthat the filling segments 104 a, 104 b, and 104 c have a substantiallysimilar volume. Each of filling segments 104 a, 104 b, and 104 c mayeach be deposited such that each segment is symmetrical. One or more ofthe filling segments 104 a, 104 b, and 104 c may deposited in such a waythat the filling does not taper along the length of the filling segment.In one embodiment, a cross sectional area of the deposited filling doesnot vary along the length of each filling segment 104 a, 104 b, and 104c. Two or more of filling segments 104 a, 104 b, and 104 c may bedeposited in such that none of the filling segments 104 a, 104 b, and104 c contacts an adjoining filling segment 104 a, 104 b, and 104 c. Inone embodiment, adjoining filling segments 104 a, 104 b, and 104 c maycontact each other substantially along the entire length of theadjoining filling segments 104 a, 104 b, and 104 c.

The methods and systems disclosed herein may also produce such fillingsegments 104 a, 104 b, and 104 c that have different organolepticcharacteristics that vary from filling segment to filling segment. Forexample, filling segments 104 a, 104 b, and 104 c may be depositedwithin a biscuit sandwich such that one filling characterizes the outertwo (e.g., 104 a and 104 c) of the three filling segments, and a secondfilling characterizes the central longitudinal filling segment 104 b. Inone embodiment, food product 100 includes a plurality of fillingsegments where no two adjoining filling segments have the sameorganoleptic properties. The differences in filling organolepticproperties may include differences in flavor, texture, rheology and/orvisual appearance. Differences in fillings may also include differentbinding characteristics (such as the ability to bind two biscuit layersto retain the integrity of the sandwich). The deposited fillings mayinclude one or more of chocolate, dairy, yogurt, crème, cheese, compoundcoatings, peanut butter, marshmallow, jams and jellies, fat-basedfillings, high water activity fillings, and low water activity fillings.One or more of the fillings may further include inclusions such aschocolate chips, fruit, bacon, candy pieces and the like. Fillings ofdifferent viscosities may be used. For example, in one embodiment, outerfilling segments 104 a and 104 c may be a higher viscosity filling thaninner filling segment 104 b. In one embodiment, the higher viscosityouter filling segments may serve to retain the lower viscosity innerfilling segment at least until the inner filling segment sufficientlysolidifies so as not to require retention.

One approach to delivering different fillings to a single biscuit is tofeed the different fillings through different filling stencils that areconfigured and dimensioned to deliver the different fillings to thesingle biscuit in a high speed continuous process. One such system fordelivering multiple segments of filling to a biscuit includes a firstfilling stencil configured and dimensioned to deliver one or more firstfilling segments to a biscuit and a second filling stencil configuredand dimensioned to add one or more additional filling segments to thebiscuit. In some embodiments, a third filling stencil may be employed todeliver one or more additional filling segment to the food item and soon. Each filling stencil may be aligned to deliver filling segments inan adjacent configuration. Each filling stencil may deliver fillingsegments that are interposed between segments that are already depositedon the biscuit. For example, a first filling stencil may deliver fillingsegments 104 a and 104 c and a second filling stencil may deliverfilling segment 104 b. In one embodiment, outer filling segments 104 aand 104 c may be delivered before inner filling segment 104 b isdelivered to biscuit 102. In an alternative embodiment, inner fillingsegment 104 b is delivered before outer filling segments 104 a and 104c. Filling segments 104 may also be delivered in patterns. In someembodiments, multiple patterns of filling may be deposited on a biscuit.Those patterns may be adjacent patterns and interposed patterns. Forexample a square first filling pattern may be supplemented with a secondpattern that fills in the square with a second filling (e.g., a fillingwith different properties).

FIG. 3 illustrates one embodiment of a filling stencil 300. Fillingstencil 300 may be a rotating filling stencil. Filling stencil 300 mayinclude substantially cylindrical body having an outer face 310. Fillingstencil 300 may further include a plurality of discharge ports 302 thatare configured to permit the discharge of a filling flowing through acentral annulus (not shown) of filling stencil 300 toward outer face 310from discharge ports 302 to, for example, a biscuit 102. Filling stencil300 may further include a discharge channel 404 (FIG. 5 and FIG. 6).Discharge channel 404 may be in communication with discharge ports 203.

Discharge ports 302 may be arranged in one or more arrays 303. Arrays303 may include a plurality of aligned discharge ports 302. Exemplarydischarge ports 302 of array 303 are aligned such that a centerline ofeach discharge port is aligned along at least a segment of thecircumference of filling stencil 300. The discharge ports 302 may beevenly spaced apart within an array 303, as illustrated in FIG. 3. Inone embodiment, discharge ports 302 are spaced apart at an angle a (FIG.4) of about 8-½ degrees. In one embodiment, the angle is selected toaccommodate the length of the biscuit. The preferred angle for biscuitsthat range from 2:1 to 2.5:1 (length vs. width) ranges from about 6.5degrees to about 10 degrees. In one embodiment, arrays 303 areconfigured in a row along a circumference of filling stencil 300 (e.g.,FIG. 3). In other embodiments, arrays 303 are arranged in curved lines,circular arrays, oval arrays, elliptical arrays and/or square arrays. Inone embodiment shaped arrays produce a perimeter of filling around anopen area. For example, an array may be configured in a perimetrical orhoop-type configuration. One or more filling stencils (e.g., multiplein-line filling stencils) may include two parallel arrays, also asillustrated in FIG. 3. In one embodiment, more than two parallel arraysmay be included in a single stencil. Arrays 303 may be oriented alongthe circumference of filling stencil 300. Arrays 303 may also beoriented axially on filling stencil 300. In an axially orientedconfiguration, filling stencils may deposit filling segments transverseto the direction of rotation 406 of filling stencil 300.

FIG. 4 is a cross section through one such array 303. As illustrated inFIG. 4, array 303 may extend within a segment 402 of the circumferenceof filling stencil 300 that is less than the full circumference offilling stencil 300. Segment 402 may be approximately 30% of the totalcircumference of filling stencil 300. Array 303 may extend around acircumference of filling stencil 300 an angle β of from about 100degrees to about 130 degrees (FIG. 4). In one embodiment, dischargeports 302 are evenly distributed within segment 402. Discharge ports 302may have a longitudinal axis that intersects the axis of rotation offilling stencil 300 (See, e.g., FIG. 4).

The number, size and shape of discharge ports 302 in a given array maybe selected based upon the volume, shape and configuration of thedesired filling segment, the viscosity of the material making up thefilling segment and/or the processing conditions and set pointsdesirable for the continuous high-speed production of food product 100.Discharge ports may be round, elongated, oval, elliptical or may beconfigured into a slot. In some embodiments a combination of shapes ofdischarge port 302 may be used. For example, a filling stencil mayinclude an array of round discharge ports and an array of elongated,oval or elliptical discharge ports. In systems that use, for example,multiple inline filling stencils to deposit fillings on single biscuits,a first stencil may include one or more arrays having round dischargeports 302 and a second in-line stencil that uses one or more arrays ofelongated, oval or elliptical discharge ports. It has been found that anarray 303 of thirteen substantially round discharge ports having adiameter of approximately 7/32 inches is effective in delivering apeanut butter filling segment having a approximately 3.5 inches in asubstantially uniform distribution.

In some embodiments, filling material may be discharged directly fromdischarge port ports 302 onto biscuit 102. By contrast, in theembodiment illustrated in FIGS. 3-6, array 303 may further include adischarge channel 404 that is in communication with discharge ports 302.Discharge channel 404 may be a depression in the outer face 310 offilling stencil 300. The depression may be configured such thatdischarge ports 302 do not terminate at outer face 310 but ratherterminate within discharge channel 404 (best illustrated in FIG. 4).Discharge channel 404 defines a boundary around array 303, in someembodiments. Discharge channel 404 can be further configured anddimensioned based upon the desired shape and size of filling segment104. In one embodiment, to produce a substantially rectangular fillingsegment 104, a discharge channel 404 that is rectangularly oriented onthe face of filling stencil 300 may be included. In another embodiment,a discharge channel with irregular boundaries may produce a fillingsegment 104 that is irregular in appearance. In some embodiments anirregular appearance is appealing to consumers who appreciate productsthat appear imperfect or homemade. In other embodiments, for example,ripples, ridges, saw-tooth configurations or a zigzag discharge channelmay be employed to produce appealing filling segment shapes andconfigurations such as those substantially matching the shape andconfiguration of the discharge channel.

In some operational embodiments, filling is discharged from dischargeports 302 and collects in discharge channel 404. In one embodiment,filling substantially fills discharge channel 404. As shown in FIG. 6,filling that has accumulated in filling channel 404 contacts or isotherwise deposited biscuit 102 as biscuit 102 passes rotating fillingstencil 300 and filling segment 104 may thereby be deposited ontobiscuit 102. In one embodiment the shape and/or volume of fillingsegment 104 substantially matches the shape and volume of dischargechannel 404.

In some embodiments (e.g., those that include multiple in-line fillingstencils), a filling stencil that first deposits filling onto a foodproduct may be configured to include a substantially continuous outerface that is interrupted only by discharge channel 404, as illustratedin FIG. 3. Because filling is discharged from the filling stencil 300 ofFIG. 3 onto a biscuit 102 that has yet to contain any filling, outersurface 310 would not disturb any previously deposited filling. In someembodiments, it is desirable to configure a second inline fillingstencil to avoid disturbing a previously deposited filling whiledepositing further filling segments onto biscuit 102.

FIG. 7 illustrates a rotatable filling stencil 700. Filling stencil 700includes an outer face 710 and a plurality of filling discharge ports702. Discharge ports 702 may be arranged in an array 703 and may furtherbe proximate discharge channel 704. In one embodiment, filling stencil700 includes one or more circumferential channels 706. Circumferentialchannels 706 may extend around the entire circumference of fillingstencil 700 (as illustrated in FIG. 7A) or may extend around only aportion of filling stencil 700. In a preferred embodiment,circumferential channels are sized and dimensioned to permit afilling-topped biscuit to pass filling stencil 700 such that fillingstencil 700 is useful for depositing an additional filling on thebiscuit without disrupting a previously deposited filling on thebiscuit. In one embodiment, circumferential channels 706 have a widththat is greater than the width of discharge channel 404. In oneembodiment, the width of discharge channel 404 is approximately the sameas the width of discharge port 302 (e.g., the diameter of a rounddischarge port). In one embodiment, filling stencils may include astabilizing wall on either side of a cream deposit. In one embodiment,the stabilizing wall may be of a width of approximately 1/16 inches. Inone embodiment, the circumferential channels 706 have a width of atleast 9/32 inches.

As can be seen from FIGS. 3 and 7, the number, size and orientation ofarrays 303 can be selected to match or dictate the number, size andorientation of circumferential channels 706. In embodiments where afirst filling stencil includes a filling port array of a different shapeor configuration, a different channel configuration may be included at asecond filling stencil to achieve the same effect. For example, thechannel may be axially aligned on the second filling stencil where afirst filling station includes an axially aligned array. For example, insystems having a first filling stencil 300 having two linear arrays 303of discharge ports 302, a second in-line filling stencil 700 may beconfigured to include two circumferential channels 706.

In one embodiment, array 703 of filling stencil 700 is interposedbetween circumferential channels 706. In one embodiment, filling stencil700 includes a rib 750. Rib 750 may be configured to extend outwardlyfrom filling stencil 700 to an outermost point on stencil 700 that issubstantially in line with outer face 710. Rib 750 may be continuous ordiscontinuous on the circumference of filling stencil 700. Duringoperation, filling discharged from filling discharge ports 702 may bedeposited onto a biscuit that has already received filling dischargedfrom discharge ports 302, for example. Rib 750 may be configured toallow the discharge of filling to a location on biscuit 102 betweenother filling deposits. For example, filling deposited through dischargeports 702 may be deposited in filling segment 104 b between fillingsegments 104 a and 104 c. In one embodiment, illustrated in FIG. 8,filling segment 104 b may be deposited adjacent to filling segments 104a and 104 c. In one embodiment, filling segment 104 b is depositedwithout overlapping filling segments 104 a and 104 c but stillcontacting substantially all of one side of filling segment 104 a and104 c. A cutting element such as cutting wire 850 may facilitate theseparation of filling segments from a filling stencil. In oneembodiment, the viscosity of filling from filling stencil 700immediately upon deposit onto biscuit 102 is lower than the viscosity offilling deposited from filling stencil 300 and those filling segments104 a and 104 c may be effective barriers to prevent filling segment 104b from migrating on biscuit 102 until the filling solidifies.

FIG. 9 illustrates one embodiment of a system 900 of the presentinvention. First filling station 930 includes rotating filling stencil300 and rotating filling stencil 700. Rotating filling stencil 300 mayinclude two rows of filling discharge ports 302 disposed on thecircumference of rotating filling stencil 300. In one embodiment,discharge ports 302 are substantially round discharge ports. A firstfilling associated with rotating filling stencil 300 is pumped from aholding or creamer pot to a tubular shaft through filling stencil 300.As the filling flows through filling station 300, filler is dischargedat an angle of from about 45 degrees to about 120 degrees where acut-off wire is located and cuts off the filler as the filling isdeposited onto the biscuit. The topped biscuit is then conveyed tosecond filling station 970. A second holding or creamer pot may be usedto supply a second filler to the second filling station 970.

In one embodiment, second filling station 970 includes a second rotatingstencil 700 having a at least one additional row of filling dischargeports 702 which are disposed on the circumference of second rotatingstencil 700. The third row of filling discharge ports 702 may include anarray of substantially elongated discharge ports. Filling dischargeports 702 may be configured and oriented to discharge filling from a riblocated approximately in the center of filling stencil 970, the ribbeing bounded by two channels oriented and configured to permit theconveyance of the topped biscuit past second filling station 970 withoutdisturbing the previously deposited filling. In one embodiment, eachsubstantially elongated discharge port is an oval-shaped discharge portthat has a major axis that is oriented transverse to the circumferenceof the second rotating filling stencil 700. The oval-shaped dischargeports may further be evenly spaced apart in the third row and the arrayof substantially oval-shaped discharge ports 702 is disposed on only onehemisphere of the second rotating stencil. In the embodiment of FIG. 9,only two fillings are applied. In other embodiments, more than twofillings are applied and in some embodiments, but more than two in-linefilling stencils. In other embodiments, the order of first fillingstation 930 and second filling station 970 are reversed. Once thefilling has been applied, the topped biscuit is then conveyed to astation where the top biscuit is applied and a pressure shoe appliespressure to the finished sandwiched product. In one embodiment, theapplication of pressure ensures that the finished product adherestogether before it is conveyed to a cooling tunnel so the food productcan be set.

System 900 further includes a conveyor 980 configured to pass a fooditem such as biscuit 102 in alignment with the first filling station 300and second filling station 700. Controller 905 is programmed to controlthe pace of conveyor 980 and the speed of rotation of filling stencil300 and filling stencil 900 to ensure that the filling discharged fromthe filling stencils is deposited on biscuit 102 in the desiredlocation. In one embodiment, system 900 is operated at sandwiching ratesof from about 120 to about 160 sandwiches per minute per row.

It will be appreciated by those skilled in the art that changes could bemade to the exemplary embodiments shown and described above withoutdeparting from the broad inventive concepts thereof. It is understood,therefore, that this invention is not limited to the exemplaryembodiments shown and described, but it is intended to covermodifications within the spirit and scope of the present invention asdefined by the claims. For example, specific features of the exemplaryembodiments may or may not be part of the claimed invention and variousfeatures of the disclosed embodiments may be combined. Unlessspecifically set forth herein, the terms “a”, “an” and “the” are notlimited to one element but instead should be read as meaning “at leastone”.

To the extent that the method does not rely on the particular order ofsteps set forth herein, the particular order of the steps should not beconstrued as limitation on the claims. The claims directed to the methodof the present invention should not be limited to the performance oftheir steps in the order written, and one skilled in the art can readilyappreciate that the steps may be varied and still remain within thespirit and scope of the present invention.

1. A method for the production of a food item having a filling, themethod comprising: a) conveying a food item to a first filling station,the filling station having a first rotating stencil with two spacedapart rows of filling discharge ports, each row comprising a pluralityof filling discharge ports disposed on the circumference of the firstrotating stencil; b) forming two filling segments by discharging thefilling through the two rows of filling discharge ports, onto the fooditem; c) conveying the food item to a second filling station, the secondfilling station having a second rotating stencil with a third row offilling discharge ports, the third row of filling discharge portscomprising a plurality of discharge ports disposed on the circumferenceof the second rotating stencil; and d) forming a third filling segmentby discharging filling through the third row of filling discharge ports,onto the food item.
 2. The method of claim 1, wherein the fillingdischarged through second filling station is deposited between the twofilling segments.
 3. The method of claim 1, wherein the two fillingsegments are deposited onto the food item after the third fillingsegment is deposited onto the food item.
 4. The method of claim 1,wherein the food item is a baked good having a rectangular configurationand wherein the step of forming two filling segments further comprisesdepositing filling longitudinally onto the baked good such that the twofilling segments are substantially parallel.
 5. The method of claim 1,wherein each of the two spaced apart rows of the filling discharge portscomprise an array of substantially round discharge ports, eachsubstantially round discharge port being substantially evenly spacedapart in each row and wherein each array is disposed on only onehemisphere of the first rotating stencil.
 6. The method of claim 1,wherein the third row of filling discharge ports comprise an array ofsubstantially oval-shaped discharge ports, each substantiallyoval-shaped discharge port having a major axis that is orientedtransverse to the circumference of the second rotating stencil, theoval-shaped discharge ports being evenly spaced apart in the third rowand wherein the array of substantially oval-shaped discharge ports isdisposed on only one hemisphere of the second rotating stencil.
 7. Themethod of claim 1, wherein the second rotating stencil further comprisestwo channels circumferentially disposed on an outer surface of thesecond rotating stencil, the third row of filling discharge ports beingdisposed between the two channels, the two channels being aligned withthe two spaced apart rows of the first rotating stencil such that inoperation the two filling segments discharged through the two rows offilling discharge ports of the first rotating stencil align with the twochannels as the food item passes the second filling station.
 8. Themethod of claim 7, wherein the second rotating stencil further comprisesa rib disposed between the two channels, the third row of fillingdischarge ports being disposed on the rib.
 9. The method of claim 1further comprising: rotating the first rotating stencil in coordinationwith the second rotating stencil such that the two filling segments andthe third filling segment are deposited onto the food item in asubstantially uniform volume and in a substantially parallelconfiguration.
 10. A system for the production of a food item having afilling thereon, the system comprising: a) a first filling stationhaving a first rotating stencil with two spaced apart rows of fillingdischarge ports, each row comprising a plurality of discharge portsdisposed on the circumference of the first rotating stencil; b) a secondfilling station having a second rotating stencil with a third row offilling discharge ports, the third row comprising a plurality ofdischarge ports disposed on the circumference of the second rotatingstencil; and d) a conveyor configured to pass a food item in alignmentwith the first filling station and the second filling station.
 11. Thesystem of claim 10, wherein the first rotating stencil is configured anddimensioned to evenly deposit two substantially parallel rows of fillingon the food item.
 12. The system of claim 10, wherein each of the twospaced apart rows of the filling discharge ports comprise an array ofsubstantially round discharge ports, each substantially round dischargeport being substantially evenly spaced apart in each row and whereineach array is disposed on only one hemisphere of the first rotatingstencil.
 13. The system of claim 10, wherein the third row of fillingdischarge ports comprise an array of substantially oval-shaped dischargeports, each substantially oval-shaped discharge port having a major axisthat is oriented transverse to the circumference of the second rotatingstencil, the oval-shaped discharge ports being evenly spaced apart inthe third row and wherein the array of substantially oval-shapeddischarge ports is disposed on only one hemisphere of the secondrotating stencil.
 14. The system of claim 10, wherein the secondrotating stencil further comprises two channels circumferentiallydisposed on an outer surface of the second rotating stencil, the thirdrow of filling discharge ports being disposed between the two channels,the two channels being aligned with the two spaced apart rows of thefirst rotating stencil such that in operation the two filling segmentsdischarged through the two rows of filling discharge ports of the firstrotating stencil align with the two channels as the food item passes thesecond filling station.
 15. The system of claim 14, wherein the secondrotating stencil further comprises a rib disposed between the twochannels, the third row of filling discharge ports being disposed on therib.
 16. The system of claim 10 further comprising: a controllerconfigured to rotate the first rotating stencil and the second rotatingstencil in coordination such that three rows of three filling segmentsare longitudinally deposited onto the food item at a substantiallyuniform volume and in a substantially parallel configuration.
 17. Amethod for the production of a food item having a filling, the methodcomprising: a) conveying a food item to a first filling station, thefilling station having a first rotating stencil with a first pluralityof filling discharge ports; b) forming at least one first fillingsegment by discharging filling, through the discharge ports, onto thefood item; c) conveying the food item to a second filling station, thesecond filling station having a second rotating stencil with a secondplurality of filling discharge ports; and d) forming at least oneadditional filling segment by discharging filling, through the secondplurality discharge ports, onto the food item wherein the at least oneadditional filling segment is disposed on the food item adjacent to theat least one first filling segment.
 18. The method of claim 17, whereinthe first plurality of filling discharge ports are arranged in an array.19. The method of claim 18, wherein the array is configured in one of arow, a circle, an ellipse, a square, a rectangle, and an irregularpattern.
 20. The method of claim 18, wherein the second plurality offilling discharge ports are arranged in a second array.
 21. The methodof claim 20, wherein the first array and the second array are configuredand dimensioned to deposit the at least one first filling segmentadjacent to the at least one additional filling segment.
 22. The methodof claim 17, wherein the at least one first filling segment comprisestwo filling segments and wherein the at least one additional fillingsegment is interposed between the two filling segments.
 23. The methodof claim 17, wherein the at least one first filling segment is depositedonto the food item in a first pattern and wherein the at least oneadditional filling segment is deposited onto the food item in a secondpattern that abuts but does not overlap the first pattern.
 24. Themethod of claim 23, wherein the first pattern comprises a firstplurality of substantially parallel rows and the second patterncomprises at least one additional row that is substantially parallel tothe first plurality of rows.
 25. The method of claim 23, wherein thefirst pattern comprises an open perimetrical shape and the secondpattern is disposed within the open perimetrical shape.
 26. The methodof claim 23, wherein the open perimetrical shape is one of a square, acircle, an ellipse and an oval having a continuous substantiallyuniformly deposited filling segment surrounding an open area on the foodproduct that is substantially free of filling.
 27. The method of claim17, wherein the at least one first filling segment has a firstorganoleptic property and the at least one additional filling segmenthas a second organoleptic property.